Keycap forming method

ABSTRACT

A keycap forming method includes the following steps. Firstly, a stabilizer bar is formed through a first male mold and a first female mold according to an injection molding process, and a keycap is formed through a second male mold and a second female mold according to the injection molding process. Then, the stabilizer bar is fixed on the first male mold, and the keycap is fixed on the second female mold. Then, the first male mold and the second female mold are stacked on each other, so that the stabilizer bar and the keycap are combined together. Then, the first male mold and the second female mold are separated from each other, so that the stabilizer bar is detached from the first male mold. By using the keycap forming method, it is not necessary to manually assemble the stabilizer bar with the keycap.

FIELD OF THE INVENTION

The present invention relates to a keyboard device, and moreparticularly to a keycap forming method for a keyboard device.

BACKGROUND OF THE INVENTION

Generally, the widely-used peripheral input device of a computer systemincludes for example a mouse device, a keyboard device, a trackballdevice, or the like. Via the keyboard device, characters or symbols canbe inputted into the computer system directly. As a consequence, mostusers and most manufacturers of input devices pay much attention to thedevelopment of keyboard devices. The subject of the present invention isrelated to a keyboard device.

FIG. 1 is a schematic top view illustrating the outer appearance of aconventional keyboard device. As shown in FIG. 1, plural key structures10 and 10′ are disposed on a top surface of the conventional keyboarddevice 1. The key structures 10 have the ordinary sizes. The keystructures 10′ are relatively longer. That is, the length of the keystructure 10 is slightly larger than the width of the key structure 10,and the length L1 of the key structure 10′ is much larger than the widthW1 of the key structure 10′. When one of the key structures 10 and 10′is depressed by the user's finger, a corresponding key signal isgenerated to the computer, and thus the computer executes a functioncorresponding to the depressed key structure. Generally, the user maydepress the key structures 10 and 10′ to input corresponding Englishletters (or symbols) or numbers or execute various functions (e.g.,F1˜F12 or Delete). For example, the conventional keyboard device 1 is akeyboard for a notebook computer.

The inner structures of the conventional keyboard device will beillustrated as follows. FIG. 2 is a schematic exploded view illustratinga portion of the conventional keyboard device and taken along aviewpoint. FIG. 3 is a schematic exploded view illustrating a portion ofthe conventional keyboard device and taken along another viewpoint.Please refer to FIGS. 1, 2 and 3. The conventional keyboard device 1comprises plural key structures 10 and 10′, a metallic base plate 11 anda membrane circuit board 12. The membrane circuit board 12 comprisesplural membrane switches 121 corresponding to the plural key structures10 and 10′. Each of the plural key structures 10 and 10′ comprises akeycap 101, at least one scissors-type connecting element 102 and arubbery elastomer 103. The scissors-type connecting element 102 isconnected between the keycap 101 and the metallic base plate 11.Moreover, the scissors-type connecting element 102 comprises a firstframe 1021 and a second frame 1022. The second frame 1022 is pivotallycoupled to the first frame 1021. Consequently, the first frame 1021 andthe second frame 1022 can be swung relative to each other. The rubberyelastomer 103 is arranged between the keycap 101 and the metallic baseplate 11. Moreover, the rubbery elastomer 103 comprises a contactingpart 1031.

While the keycap 101 of any key structure 10 or 10′ is depressed andmoved downwardly relative to the metallic base plate 11, the first frame1021 and the second frame 1022 of the scissors-type connecting element102 are switched from an open-scissors state to a stacked state.Moreover, as the keycap 101 is moved downwardly to compress the rubberyelastomer 103, the corresponding membrane switch 121 is pushed andtriggered by the contacting part 1031 of the rubbery elastomer 103.Consequently, the membrane circuit board 12 generates a correspondingkey signal. When the keycap 101 of the key structure 10 or 10′ is nolonger depressed, the keycap 101 is moved upwardly relative to themetallic base plate 11 in response to an elastic force of the rubberyelastomer 103. Meanwhile, the first frame 1021 and the second frame 1022are switched from the stacked state to the open-scissors state again,and the keycap 101 is returned to its original position.

In the keyboard device 1, the key structures 10′ and the key structures10 are distinguished. As shown in the drawings, the length L1 of the keystructure 10′ is much larger than the width W1 of the key structure 10′.Since the length L1 of the keycap 101 of the key structure 10′ isrelatively longer, the keycap 101 is readily rocked while the keystructure 10′ is depressed. That is, the operating smoothness of the keystructure 10′ is adversely affected, and even the tactile feel of theuser is impaired. For increasing the operating smoothness of the keystructure 10′, the key structure 10′ is further equipped with a specialmechanism. For example, the key structure 10′ further comprises a firststabilizer bar 104, a second stabilizer bar 105 and plural hooks 106.The first stabilizer bar 104 comprises a first linking bar part 1041 andtwo first hook parts 1042. The two first hook parts 1042 are located attwo ends of the first stabilizer bar 104, respectively. The secondstabilizer bar 105 comprises a second linking bar part 1051 and twosecond hook parts 1052. The two second hook parts 1052 are located attwo ends of the second stabilizer bar 105, respectively.

The metallic base plate 11 comprises a first connecting structure 111and a second connecting structure 112. The first connecting structure111 and the second connecting structure 112 are protruded upwardly, andpenetrated through the membrane circuit board 12. The first connectingstructure 111 comprises a first locking hole 1111 and a third lockinghole 1112. The second connecting structure 112 comprises a secondlocking hole 1121 and a fourth locking hole 1122. The second lockinghole 1121 corresponds to the first locking hole 1111. The fourth lockinghole 1122 corresponds to the third locking hole 1112.

The first linking bar part 1041 of the first stabilizer bar 104 and thesecond linking bar part 1051 of the second stabilizer bar 105 arepivotally coupled to the corresponding hooks 106 of the keycap 101 ofthe key structure 10′. The two first hook parts 1042 of the firststabilizer bar 104 are penetrated through the first locking hole 1111 ofthe first connecting structure 111 and the second locking hole 1121 ofthe second connecting structure 112, respectively. The two second hookparts 1052 of the second stabilizer bar 105 are penetrated through thethird locking hole 1112 of the first connecting structure 111 and thefourth locking hole 1122 of the second connecting structure 112,respectively.

FIG. 4 schematically illustrates the actions of the first stabilizer barand the second stabilizer bar of the conventional keyboard device. Whilethe keycap 101 of the key structure 10′ is moved upwardly or downwardlyrelative to the metallic base plate 11, the first stabilizer bar 104 ismoved in a first direction D11 or a second direction D12 and rotated ina first rotating direction D13 or a second rotating direction D14.Similarly, the second stabilizer bar 105 is moved in the first directionD11 or the second direction D12 and rotated in the first rotatingdirection D13 or the second rotating direction D14. By the firststabilizer bar 104 and the second stabilizer bar 105, the key structure10′ is kept stable and not inclined while the key structure 10′ is movedupwardly or downwardly relative to the metallic base plate 11. Moreover,the uses of the first stabilizer bar 104 and the second stabilizer bar105 are helpful to increase the strength of the keycap 101.

The arrangements of the first stabilizer bar 104 and the secondstabilizer bar 105 have the above advantages. However, since it isnecessary to assemble the first stabilizer bar 104 and the secondstabilizer bar 105 with the keycap 101, the fabricating cost of thekeyboard device 1 is increased. Generally, the process of assembling thefirst stabilizer bar 104 and the second stabilizer bar 105 with thekeycap 101 is manually performed. The manual assembling process istime-consuming and labor-intensive. Moreover, since the assemblingprocess is readily erroneous, the hooks 106 of the keycap 101 arepossibly broken.

SUMMARY OF THE INVENTION

An object of the present invention provides a keycap forming method forreducing the fabricating cost of a keyboard device.

In accordance with an aspect of the present invention, there is provideda keycap forming method. The keycap forming method includes thefollowing steps. In a step A, a stabilizer bar is formed through a firstmale mold and a first female mold according to an injection moldingprocess. In a step B, a keycap is formed through a second male mold anda second female mold according to the injection molding process. In astep C, the first male mold and the first female mold are separated fromeach other, and the second male mold and the second female mold areseparated from each other. In a step D, the first male mold and thesecond female mold are aligned with and stacked on each other, so thatthe stabilizer bar and the keycap are combined together. In a step E,the first male mold and the second female mold are separated from eachother, so that the stabilizer bar is detached from the first male mold.

In an embodiment, the step (A) includes steps (A1) and (A2). In the step(A1), the first male mold and the first female mold are stacked on eachother. In the step (A2), a first molding material is injected into aspace between the first male mold and the first female mold according tothe injection molding process. The first molding material is filled intoa first molding groove of the first male mold and a second moldinggroove of the first female mold. Consequently, the stabilizer bar isformed.

In an embodiment, the step (E) includes steps (E1) and (E2). In the step(E1), the first male mold and the second female mold are separated fromeach other. In the (E2), plural fixing structures of the first male moldto be shrunk back into the first male mold to externally push thestabilizer bar. Consequently, the stabilizer bar is detached from theplural fixing structures and fixed on the keycap.

Preferably, in the step (E), a first segment of the stabilizer bar isfixed in the hook of the keycap, and a second segment of the stabilizerbar is fixed on plural fixing structures of the first male mold.

From the above descriptions, the present invention provides the keycapforming method. Firstly, the stabilizer bar is formed through the firstmale mold and the first female mold, and the keycap is formed throughthe second male mold and the second female mold. Then, the stabilizerbar is moved through the first male mold, the second male mold, thefirst female mold and the second female mold. Moreover, the stabilizerbar and the keycap are combined together during the process of formingthe keycap. After the stabilizer bar is separated from the first malemold, the keycap with the combined stabilizer bar is produced. Inaccordance with the method of the present invention, it is not necessaryto manually assemble the stabilizer bar with the keycap. The keycapforming method of the present invention is completely automatic. Theassembling precision of the keycap forming method of the presentinvention is higher than that of the manual assembling method.Consequently, the possibility of causing damage of the keycap during theassembling process will be largely reduced.

The above objects and advantages of the present invention will becomemore readily apparent to those ordinarily skilled in the art afterreviewing the following detailed description and accompanying drawings,in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic top view illustrating the outer appearance of aconventional keyboard device;

FIG. 2 is a schematic exploded view illustrating a portion of theconventional keyboard device and taken along a viewpoint;

FIG. 3 is a schematic exploded view illustrating a portion of theconventional keyboard device and taken along another viewpoint;

FIG. 4 schematically illustrates the actions of the first stabilizer barand the second stabilizer bar of the conventional keyboard device;

FIG. 5 schematically illustrates a first male mold, a second male mold,a first female mold and a second female mold of a device for performinga keycap forming method according to an embodiment of the presentinvention and taken along a viewpoint;

FIG. 6 schematically illustrates the first male mold, the second malemold, the first female mold and the second female mold of the device forperforming the keycap forming method according to the embodiment of thepresent invention and taken along another viewpoint;

FIG. 7 is a flowchart illustrating a keycap forming method according toan embodiment of the present invention;

FIG. 8 schematically illustrates a step of performing the injectionmolding process according to the keycap forming method of the presentinvention;

FIG. 9 schematically illustrates a step of fixing the stabilizer bar onthe first male mold according to the keycap forming method of thepresent invention;

FIG. 10 schematically illustrates a step of fixing the keycap on thesecond female mold according to the keycap forming method of the presentinvention;

FIG. 11 schematically illustrates a step of aligning the first male moldwith the second female mold according to the keycap forming method ofthe present invention;

FIG. 12 schematically illustrates a step of stacking the first male moldand the second female mold on each other according to the keycap formingmethod of the present invention; and

FIG. 13 is a schematic perspective view illustrating a keycap producedby the keycap forming process according to the embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

For overcoming the drawbacks of the conventional technologies, thepresent invention provides a keycap forming method. The device forperforming the keycap forming method will be illustrated as follows.

Please refer to FIGS. 5 and 6. FIG. 5 schematically illustrates a firstmale mold, a second male mold, a first female mold and a second femalemold of a device for performing a keycap forming method according to anembodiment of the present invention and taken along a viewpoint. FIG. 6schematically illustrates the first male mold, the second male mold, thefirst female mold and the second female mold of the device forperforming the keycap forming method according to the embodiment of thepresent invention and taken along another viewpoint. In FIGS. 5 and 6, afirst male mold 21, a second male mold 22, a first female mold 23, asecond female mold 24, a moving mechanism 25, a first storage tank 26, asecond storage tank 27, a fixing plate 28, a stabilizer bar 3 and akeycap 4 are shown. The stabilizer bar 3 comprises a first segment 31and a second segment 32. The keycap 4 comprises plural hooks 41. Thefirst male mold 21 comprises plural first fixing posts 211, pluralfixing structures 212 corresponding to the stabilizer bar 3, and a firstmolding groove 213 corresponding to the stabilizer bar 3. The secondmale mold 22 comprises plural second fixing posts 221, a raisedstructure 222 corresponding to the keycap 4, plural hook recesses 223corresponding to the plural hooks 41, and an ejecting mechanism 224. Thefirst molding groove 213 is a core of the first male mold 21. The raisedstructure 222 and the plural hook recesses 223 are collaborativelydefined as a core of the second male mold 22. The moving mechanism 25 isconnected with the first male mold 21 and the second male mold 22.Moreover, the first male mold 21 and the second male mold 22 are movableor rotatable by the moving mechanism 25.

The first female mold 23 is fixed on the fixing plate 28. The firstfemale mold 23 comprises a second molding groove 231 corresponding tothe stabilizer bar 3, plural first fixing holes 232, and a first feedingchannel 233. The second female mold 24 is fixed on the fixing plate 28and located beside the first female mold 23. The second female mold 24comprises plural second fixing holes 241, a concave structure 242corresponding to the keycap 4, and a second feeding channel 243. Thesecond molding groove 231 is a cavity of the first female mold 23. Theconcave structure 242 is a cavity of the second female mold 24. Thefixing plate 28 is used for fixing the first female mold 23 and thesecond female mold 24. The fixing plate 28 comprises a first opening 281and a second opening 282. After the first female mold 23 and the secondfemale mold 24 are fixed on the fixing plate 28, the first opening 281is aligned with the first feeding channel 233 and the second opening 282is aligned with the second feeding channel 243. A first molding materialis contained in the first storage tank 26. Moreover, a portion of thefirst storage tank 26 is inserted into the first opening 281. A secondmolding material is contained in the second storage tank 27. A portionof the second storage tank 27 is inserted into the second opening 282.

In this embodiment, the first female mold 23 and the second female mold24 are fixed on the fixing plate 28 and not movable. The first male mold21 and the second male mold 22 are connected with the moving mechanism25. Consequently, the first male mold 21 and the second male mold 22 aremoved or rotated with the moving mechanism 25. It is noted that numerousmodifications and alterations may be made while retaining the teachingsof the invention. For example, in another embodiment, the first femalemold and the second female mold are connected with the moving mechanism,and the first male mold and the second male mold are fixed on the fixingplate. Consequently, the first female mold and the second female moldare moved or rotated with the moving mechanism, but the first male moldand the second male mold are not movable.

The connecting relationship between the keycap 4 and the scissors-typeconnecting element is not the subject of the present invention.Consequently, the hooks of the keycap 4 to be connected with thescissors-type connecting element are not shown in FIG. 6. Forsuccinctness, only the hooks 41 of the keycap 4 corresponding to thestabilizer bar 3 are shown in FIG. 6.

A keycap forming method of the present invention will be described asfollows. FIG. 7 is a flowchart illustrating a keycap forming methodaccording to an embodiment of the present invention. The keycap formingmethod comprises the following steps.

In a step A, a stabilizer bar is formed through a first male mold and afirst female mold according to an injection molding process. In a stepB, a keycap is formed through a second male mold and a second femalemold according to the injection molding process. In a step C, the firstmale mold and the first female mold are separated from each other, andthe second male mold and the second female mold are separated from eachother. In a step D, the first male mold and the second female mold arealigned with and stacked on each other, so that the stabilizer bar andthe keycap are combined together. In a step E, the first male mold andthe second female mold are separated from each other, so that thestabilizer bar is detached from the first male mold.

The step A comprises steps A1 and A2. In the step A1, the first malemold and the first female mold are stacked on each other. In the stepA2, a first molding material is injected according to the injectionmolding process, so that the stabilizer bar is formed.

The step B comprises steps B1 and B2. In the step B1, the second malemold and the second female mold are stacked on each other. In the stepB2, a second molding material is injected according to the injectionmolding process, so that the keycap is formed.

The step C comprises steps C1 and C2. In the step C1, the first malemold and the first female mold are separated from each other, and thestabilizer bar is fixed on the first male mold. In the step C2, thesecond male mold and the second female mold are separated from eachother, and the keycap is fixed on the second female mold.

The step D comprises steps D1 and D2. In the step D1, the first malemold and the second male mold are moved. In the step D2, the first malemold and the second female mold are aligned with and stacked on eachother.

The step E comprises steps E1 and E2. In the step E1, the first malemold and the second female mold are separated from each other. In thestep E2, the plural fixing structures are shrunk back into the firstmale mold to externally push the stabilizer bar.

Hereinafter, the operations of the keycap forming method and theassociated molds will be described with reference to FIGS. 8 and 9. FIG.8 schematically illustrates a step of performing the injection moldingprocess according to the keycap forming method of the present invention.FIG. 9 schematically illustrates a step of fixing the stabilizer bar onthe first male mold according to the keycap forming method of thepresent invention. Firstly, in the step A1, the moving mechanism 25 ismoved in a first direction V1. As the first male mold 21 is moved withthe moving mechanism 25, the first male mold 21 and the first femalemold 23 are stacked on each other (see FIG. 8). When the first male mold21 and the first female mold 23 are stacked on each other, the pluralfirst fixing posts 211 are inserted into the corresponding first fixingholes 232. Consequently, the first male mold 21 and the first femalemold 23 are not shifted toward the left and right sides. Moreover, whilethe first male mold 21 and the first female mold 23 are stacked on eachother, the plural fixing structures 212 of the first male mold 21 arepushed by the first female mold 23. Consequently, the plural fixingstructures 212 are shrunk back into the first male mold 21.

In the step A2, the first molding material is injected into the spacebetween the first male mold 21 and the first female mold 23 through thefirst male mold 21 and the first female mold 23 according to theinjection molding process. Consequently, the stabilizer bar 3 is formed.During the injection molding process, the first molding material isinjected from the first storage tank 26 to the first molding groove 213of the first male mold 21 and the second molding groove 231 of the firstfemale mold 23 through the first feeding channel 233. Consequently, thestabilizer bar 3 is formed in the first molding groove 213 and thesecond molding groove 231. In an embodiment, the first molding materialis made of a plastic material with higher rigidity.

While the step A is performed, the step B1 is performed to move themoving mechanism 25 in the first direction V1. As the second male mold22 is moved with the moving mechanism 25, the second male mold 22 andthe second female mold 24 are stacked on each other (see FIG. 8). Whenthe second male mold 22 and the second female mold 24 are stacked oneach other, the plural second fixing posts 221 are inserted into thecorresponding second fixing holes 241. Consequently, the second malemold 22 and the second female mold 24 are not shifted toward the leftand right sides. In the step B2, the second molding material is injectedinto the space between the second male mold 22 and the second femalemold 24 (i.e., the space between the raised structure 222 and theconcave structure 242). Consequently, the keycap 4 is formed. During theprocess of forming the keycap 4, the injected second molding material isfilled into the plural hook recesses 223 of the second male mold 22.Consequently, the plural hooks 41 of the keycap 4 are formed. In anembodiment, the second molding material is made of a plastic material.

Please refer to FIGS. 9 and 10. FIG. 10 schematically illustrates a stepof fixing the keycap on the second female mold according to the keycapforming method of the present invention. After the step A and the step Bare completed, the step C is performed. In the step C1, the movingmechanism 25 is moved in a second direction V2, which is opposite to thefirst direction V1. As the first male mold 21 is moved with the movingmechanism 25, the first male mold 21 and the first female mold 23 areseparated from each other. Meanwhile, the plural fixing structures 212are protruded out of the first male mold 21. That is, the plural fixingstructures 212 are protruded out in the first direction V1, so that thestabilizer bar 3 is fixed on the plural fixing structures 212. In suchway, the stabilizer bar 3 is not detached from the first male mold 21.In this embodiment, the second segment 32 of the stabilizer bar 3 isfixed on the plural fixing structures 212.

In the step C2, the moving mechanism 25 is moved in the second directionV2 to move the second male mold 22. Consequently, the second male mold22 and the second female mold 24 are separated from each other, and thekeycap 4 is fixed in the concave structure 242 of the second female mold24. While the moving mechanism 25 is moved in the second direction V2 tomove the second male mold 22, the ejecting mechanism 224 of the secondmale mold 22 is moved in the first direction V1. That is, the ejectingmechanism 224 is protruded out of the second male mold 22 to push thekeycap 4 in the first direction V1. Consequently, the keycap 4 isdetached from the second male mold 22. At the same time, the keycap 4 isfixed in the concave structure 242 of the second female mold 24. In anembodiment, the second ejecting mechanism 224 of the second male mold 22is an angle lifter. The operations of the angle lifter are well known tothose skilled in the art, and are not redundantly described herein.

Please refer to FIGS. 7, 11 and 12. FIG. 11 schematically illustrates astep of aligning the first male mold with the second female moldaccording to the keycap forming method of the present invention. FIG. 12schematically illustrates a step of stacking the first male mold and thesecond female mold on each other according to the keycap forming methodof the present invention.

After the step C is performed. The step D1 is performed. As the movingmechanism 25 is rotated in a rotating direction S, the first male mold21 and the second male mold 22 are moved. Consequently, the first malemold 21 is away from the first female mold 23, and the first male mold21 is close to the second female mold 24. Meanwhile, the first male mold21 and the second female mold 24 are aligned with each other. The methodof aligning the first male mold 21 with the second female mold 24 iswell known to those skilled in the art, and is not redundantly describedherein. The fixing structures 212 of the first male mold 21 and thesecond female mold 24 are precisely designed. Consequently, when thefirst male mold 21 is moved to the position under the second female mold24 and aligned with the second female mold 24, the plural hooks 41 ofthe keycap 4 are located over the first segment 31 of the stabilizer bar3.

After the first male mold 21 and the second female mold 24 are alignedwith each other, the step D2 is performed. The rotation of the movingmechanism 25 is stopped, and the moving mechanism 25 is moved in thefirst direction V1 to move the first male mold 21. Consequently, thefirst male mold 21 and the second female mold 24 are stacked on eachother (see FIG. 12). When the first male mold 21 and the second femalemold 24 are stacked on each other, the plural first fixing posts 211 areinserted into the corresponding second fixing holes 241. Consequently,the first male mold 21 and the second female mold 24 are not shiftedtoward the left and right sides. Moreover, when the first male mold 21and the second female mold 24 are stacked on each other, the stabilizerbar 3 and the keycap 4 are combined together. However, the stabilizerbar 3 is still connected with the first male mold 21. In other words,the first segment 31 of the stabilizer bar 3 is fixed in the pluralhooks 41 of the keycap 4, and the second segment 32 of the stabilizerbar 3 is fixed on the plural fixing structures 212 of the first malemold 21.

After the stabilizer bar 3 and the keycap 4 are combined together, thestep E1 is performed. In the step E1, the moving mechanism 25 is movedin the second direction V2. As the first male mold 21 is moved with themoving mechanism 24, the first male mold 21 and the second female mold24 are separated from each other. In the step E2, the plural fixingstructures 212 are shrunk back into the first male mold 21, so that thestabilizer bar 3 is externally pushed by the first male mold 21.Meanwhile, the stabilizer bar 3 is detached from the plural fixingstructures 212, and the stabilizer bar 3 is only fixed on the pluralhooks 41 of the keycap 4. Consequently, the stabilizer bar 3 and thekeycap 4 are combined together (see FIG. 13). The keycap forming methodof the present invention is completed.

The following three aspects should be specially described.

Firstly, in the step E of the above embodiment, the plural fixingstructures 212 are shrunk back into the first male mold 21.Consequently, the stabilizer bar 3 is externally pushed by the firstmale mold 21, and the stabilizer bar 3 is detached from the first malemold 21. It is noted that numerous modifications and alterations may bemade while retaining the teachings of the invention. For example, inanother embodiment, the first male mold is equipped with an ejectingmechanism corresponding to the stabilizer bar. Consequently, while thefirst male mold and the second female mold are separated from eachother, a stronger force is provided to externally push the stabilizerbar to facilitate separating the stabilizer bar from the first malemold.

Secondly, the first feeding channel corresponding to the first storagetank is not restrictedly formed in the first female mold, and the secondfeeding channel corresponding to the second storage tank is notrestrictedly formed in the second female mold. That is, the method ofthe present invention may be varied according to the practicalrequirements. For example, the first feeding channel is formed in thefirst male mold, the first storage tank is connected with the first malemold, the second feeding channel is formed in the second male mold, andthe second storage tank is connected with the second male mold.

Thirdly, in the above embodiment, the first male mold and the secondmale mold are not simultaneously moved. That is, the method of thepresent invention may be varied according to the practical requirements.For example, the first male mold is connected with a first movingmechanism, and the second male mold is connected with a second movingmechanism. Consequently, the movement of the first male mold and themovement of the second male mold are independent from each other. Underthis circumstance, the step A and the step B are individually performedbut are not simultaneously performed. Moreover, the sequence of the stepA and the step B is not restricted. However, the step A and the step Bare performed before the step C.

From the above descriptions, the present invention provides the keycapforming method. Firstly, the stabilizer bar is formed through the firstmale mold and the first female mold, and the keycap is formed throughthe second male mold and the second female mold. Then, the stabilizerbar is moved through the first male mold, the second male mold, thefirst female mold and the second female mold. Moreover, the stabilizerbar and the keycap are combined together during the process of formingthe keycap. After the stabilizer bar is separated from the first malemold, the keycap with the combined stabilizer bar is produced. Inaccordance with the method of the present invention, it is not necessaryto manually assemble the stabilizer bar with the keycap. The keycapforming method of the present invention is completely automatic. Theassembling precision of the keycap forming method of the presentinvention is higher than that of the manual assembling method.Consequently, the possibility of causing damage of the keycap during theassembling process will be largely reduced.

While the invention has been described in terms of what is presentlyconsidered to be the most practical and preferred embodiments, it is tobe understood that the invention needs not be limited to the disclosedembodiments. On the contrary, it is intended to cover variousmodifications and similar arrangements included within the spirit andscope of the appended claims which are to be accorded with the broadestinterpretation so as to encompass all modifications and similarstructures.

What is claimed is:
 1. A keycap forming method, comprising steps of: (A)forming a stabilizer bar through a first male mold and a first femalemold according to an injection molding process, wherein the first malemold comprises plural fixing structures corresponding and laterallyadjacent to the stabilizer bar and configured to shrink back into thefirst male mold when forming the stabilizer bar; (B) forming a keycapthrough a second male mold and a second female mold according to theinjection molding process; (C) separating the first male mold from thefirst female mold, and separating the second male mold from the secondfemale mold, wherein the plural fixing structures are configured toprotrude out of the first male mold to fix the stabilizer bar on thefirst male mold when separating the first male mold from the firstfemale mold; wherein the second male mold comprises an ejectingmechanism configured to protrude out of the second male mold to push anddetach the keycap from the ejecting mechanism and the second male moldwhen separating the second male mold from the second female mold, sothat the keycap is fixed on the second female mold; (D) allowing thefirst male mold and the second female mold to be aligned with andstacked on each other, so that the stabilizer bar fixed on the firstmale mold and the keycap fixed on the second female mold are combinedtogether; and (E) separating the first male mold from the second femalemold, so that the stabilizer bar is detached from the first male mold.2. The keycap forming method according to claim 1, wherein the step (A)comprises steps of: (A1) allowing the first male mold and the firstfemale mold to be stacked on each other; and (A2) injecting a firstmolding material into a space between the first male mold and the firstfemale mold according to the injection molding process, wherein thefirst molding material is filled into a first molding groove of thefirst male mold and a second molding groove of the first female mold, sothat the stabilizer bar is formed.
 3. The keycap forming methodaccording to claim 2, wherein the step (E) comprises steps of: (E1)separating the first male mold from the second female mold; and (E2)allowing the plural fixing structures of the first male mold to beshrunk back into the first male mold to externally push the stabilizerbar, so that the stabilizer bar is detached from the plural fixingstructures and fixed on the keycap.
 4. The keycap forming methodaccording to claim 1, wherein the step (B) comprises steps of: (B1)allowing the second male mold and the second female mold to be stackedon each other; and (B2) injecting a second molding material into a spacebetween the second male mold and the second female mold according to theinjection molding process, so that the keycap is formed, wherein whenthe second molding material is filled into a recess of the second malemold, a hook of the keycap is formed.
 5. The keycap forming methodaccording to claim 4, wherein in the step (D), a first segment of thestabilizer bar is fixed in the hook of the keycap, and a second segmentof the stabilizer bar is fixed on the plural fixing structures of thefirst male mold.
 6. The keycap forming method according to claim 4,wherein in the step (B), the second male mold is moved in a firstdirection through a moving mechanism, so that the second male mold andthe second female mold are stacked on each other, wherein in the step(C), the second male mold is moved in a second direction through themoving mechanism, so that the second male mold and the second femalemold are separated from each other.
 7. The keycap forming methodaccording to claim 1, wherein the step (D) comprises steps of: (D1)moving the first male mold and the second male mold, so that the secondmale mold is away from the second female mold and the first male mold isclose to the second female mold; and (D2) allowing the first male moldand the second female mold to be aligned with each other, moving thefirst male mold, and allowing the first male mold and the second femalemold to be stacked on each other.
 8. The keycap forming method accordingto claim 7, wherein in the step (D1), a moving mechanism is rotated in arotating direction, and the first male mold and the second male mold arecorrespondingly rotated with the moving mechanism, so that the secondmale mold is away from the second female mold and the first male mold isclose to the second female mold.